Method of making hairpieces

ABSTRACT

An improved method of making a hairpiece of the type worn to cover a bald spot or the like on a human head. The method includes the obtaining of the proper pattern from the wearer and the preparation of a form on which the artificial hair is laid to the shape of the bald spot to be covered. The hair is laid in a retaining and transfer means, filling the desired pattern and following which the hair and the means are transferred to a frame for manufacture of the hairpiece base. The inner ends of the hairs, which extend through the retaining and transfer means, are trimmed to a desired and relatively short length. A plurality of thin coats of a thermoplastic material are sprayed across the inner ends of the hairs to create a subbase of a depth of about one-third the length of the inner ends of the hairs. After setting for a period of time, a coating of an epoxy resin adhesive is spread over the subbase and the inner ends of the hairs to a depth of approximately another one-third of the length of exposed inner ends of the hairs. Yet another plurality of thin coats of thermoplastic material are sprayed over the layer of epoxy resin adhesive to the remaining depth of the inner ends of the hairs, which coats are allowed to set for a period of time. The hairs and base are then removed from the transfer frame and mounted on the previously marked location on the head form. The hairs are shaped to the desired lay and suitably held in place. The head form and hairpiece are then placed under heat for a period of time to cure the materials and conform the base to the head form. Upon curing and cooling, the hairpiece may be mounted on the wearer and the hair trimmed and set for compatibility with the remaining natural hair.

United States Patent Nolen 5] Feb. 29, 1972 [54] METHOD OF MAKING HAIRPIECES Clara F. Nolen, 2253 Hampton Road, Pontiac, Mich. 48054 [22] Filed: Apr.3, 1970 [21] Appl.No.: 25,426

[72] Inventor:

[52] US. Cl....

Primary Examiner-Russell R. Kinsey Assistant ExaminerJ. O. Lever Attorney-Fisher & Schmidt [5 7] ABSTRACT An improved method of making a hairpiece of the type worn to cover a bald spot or the like on a human head. The method includes the obtaining of the proper pattern from the wearer and the preparation of a form on which the artificial hair is laid to the shape of the bald spot to be covered. The hair is laid in a retaining and transfer means, filling the desired pattern and following which the hair and the means are transferred to a frame for manufacture of the hairpiece base. The inner ends of the hairs, which extend through the retaining and transfer means, are trimmed to a desired and relatively short length. A plurality of thin coats of a thermoplastic material are sprayed across the inner ends of the hairs to create a subbase of a depth of about one-third the length of the inner ends of the hairs. After setting for a period of time, a coating ofan epoxy resin adhesive is spread over the subbase and the inner ends of the hairs to a depth of approximately another one-third of the length of exposed inner ends of the hairs. Yet another plurality of thin coats of thermoplastic material are sprayed over the layer of epoxy resin adhesive to the remaining depth of the inner ends of the hairs, which coats areallowed to set for a period of time. The hairs and base are then removed from the transfer frame and mounted on the previously marked location on the head form. The hairs are shaped to the desired lay and suitably held in place. The head fonn and hairpiece are then placed under heat for a period of time to cure the materials and conform the base to the head form. Upon curing and cooling, the hairpiece may be mounted on the wearer and the hair trimmed and set for compatibility with the remaining natural hair.

6 Claims, 3 Drawing Figures METHOD or MAKING I-IAIRPIECES This invention relates to the art of manufacturing artificial hairpieces and more particularly to a method of making a base for an artificial hairpiece.

Many people, when faced with the loss of some or all of their natural hair, desire to cover a bald spot with an artificial hairpiece manufactured from hair mounted in a suitable base. The hairpiece is so constructed as to exactly cover the bald portion and the hair and is dyed and otherwise shaped to match the remaining hair of the wearer. Such hairpiece is normally mounted on the head by suitable adhesive means and may be worn day and night or removed from time to time.

There are many known methods of manufacturing artificial hairpieces for the purpose of covering bald spots. One such method includes the individual placement of hairs into a suitable base, which is obviously a tedious, time consuming and expensive process. Other methods include weaving of the hair at the base ends so that the hairs will not separate and fall out, which again is a time consuming and expensive process. Yet another well-known method is to lay up the hairs in a suitable frame with some sort of retaining means to secure the hairs in place and then providing a thick coating of suitable material to form a hairpiece base and to hold the hairs in place.

Most of the well-known methods of manufacturing hairpieces, besides being tedious and expensive processes, have a number of disadvantages for the wearer. Oftentimes the securement of the hair to the base is imperfect and the hairs will pull out or fall out as the hairpiece is worn. This may also be caused by the natural body oils and acids which react adversely with the materials of the hairpiece base and loosen the individual hairs. Generally, there is no control over the way in which the individual hairs will lay once the hairpiece is manufactured, so that should the hairpiece include a portion of a natural part great difficulty is experienced in maintaining the hairs in their proper positions. In many of the known methods, shrinkage of the materials from which the base is made, either during the manufacturing process or during the wearing thereof, causes great difi'rculty in maintaining a proper fit and in properly securing the hairpiece to the head. Heat, cold and other weather conditions often effect the hairpiece, either in shrinkage or in losing the hair from the base material, and it is often necessary to provide such a thick base structure that the hairpiece is of great bulk, looking unnatural and being uncomfortable for the wearer.

The method of which this invention is embodied comprises,

hairpiece base. During this process, the anchored ends of the hairs assume the desired direction so that the hairs can be easily shaped and made compatible with the remaining hair of the wearer. Upon cooling and demounting from the head form, the hairpiece may be disposed on the head of the wearer and the hairs trimmed and shaped to the desires of the wearer.

A hairpiece manufactured in accordance with the foregoing method provides a great degree of control over the lay of the hair for compatibility with the remaining hair of the wearer. The hairs are securely anchored in the base structure and avoid the tendency to pull out of the base. The base itself is generally, the laminating of a base structure for the hairpiece in such way and under such conditions as to securely retain the hairs in the base structure and to provide a degree of control over the lay of the hairs for ease in making the hairpiece compatible with the remaining natural hair of the wearer. The method includes the laying up of the hair in a retaining and transfer means and transporting the laid up hair to a frame for construction of the base. The inner ends of the hairs, laid in a pattern exactly conforming to the bald spot of the wearer, are trimmed to a very short and even length. A plurality of thin coats of thermoplastic material are sprayed over the exposed inner ends of the hairs to a depth of about one-third of the length thereof. After the thermoplastic material has had a predetermined time to set, a coating of an epoxy resin adhesive is spread over the thermoplastic material and to a depth of approximately onethird of the length of the inner ends of the hairs. A brief setting period is provided for the epoxy resin adhesive, following which a second plurality of thin coats of thermoplastic material are sprayed over the adhesive layer and to the remaining depth of the inner ends of the hairs. The base so formed is then removed from the retaining and transfer frame and properly placed on a head form to provide the curvature necessary to mount the hairpiece on the wearer. The hair is then shaped to the desired direction and held in place by any suitable means, following which the head form and the hairpiece are placed in an oven for a predetermined time and at a predetermined heat to cure the thermoplastic and epoxy resin materials. The result is a properly formed and properly curved and as the hairs are securely anchored and because of the materials used, it is possible to set the hairpiece with hair oils, hair gels, sprays and the like.

These and other advantages will become more apparent from the following description, used to illustrate a preferred embodiment of the invention when taken with the a accompanying drawing in which:

FIG. 1 is a schematic view of the transfer and retaining means showing the manner in which the hairs are originally laid.

FIG. 2 is a schematic view of the frame in which the retaining and transfer means are mounted during the formation of the base structure.

FIG. 3 is a partial cross-sectional view of a hairpiece manufactured in accordance with the method of the invention.

Referring more particularly to the drawing, where the various figures are for the purpose of illustrating a preferred embodiment of the invention only and not for purposes of limiting the same, FIGS. 1 and 2 schematically represent a wellknown method of laying up the hairs for the hairpiece and assist in illustrating the manner in which the method is carried out.

As shown in FIG. 1, a pattern sheet, indicated generally by the numeral 10, is shown to include an opening 12 which is shaped to the planer developed form of the bald spot on the wearer. Behind the opening 12 and in the laying up of the hairs a magnetic strip 14, which may have dimensions somewhere in the neighborhood of one-half inch by one-sixteenth inch by six inches in length, is first placed on the rearwardly extending portion 16 of the pattern form 10. Over the top of the lowest magnet 14 and across the opening 12 are placed a plurality of hairs, indicated generally by the numeral 18. When the desired number of hairs are so located, a second magnetic strip is placed over the hairs on the first magnetic strip, the magnetic strips being attracted to each other and clamping the hairs in between. A second layer of hairs 18 are placed over the second magnetic strip and across the opening 12 to the desired degree, at which point a third magnetic strip 14 clamps the second row of hairs to the second magnetic strip 14. This process is continued until the entire opening 12 is filled with hairs 18 extendingoutwardly therefrom and extending rearwardly from the magnets as viewed in FIG. 1.

When the opening 12 in the pattern form 10 is completely filled with the hairs 18, the magnetic strips 14 and hairs 18 are transported to a suitable frame, indicated generally by the numeral 20 in FIG. 2, where they are set in horizontal position and with the inner ends of the hairs extending upwardly from between the magnetic strips 14. The magnetic strips are then suitably clamped in place, as indicated schematically by arrows 22, the clamping force being provided in any convenient and wellknown manner. The inner ends of the hairs 18 are then trimmed to an even and short length, somewhere in the neighborhood of one-sixteenth to one thirty-second of an inch.

The base structure is manufactured from a plurality of materials that are sprayed over the hairs 18, the first of such materials being a thermoplastic material, and preferably an acrylic polymer emulsion which is a well-known and readily available material. One such acrylic polymer emulsion is manufactured under the trade name Liquitex and is often used for the protection of paintings or the like. The acrylic polymer emulsion is available in numerous matte finishes, and in the preparation of the hairpiece base the first coat sprayed over the hairs 18 on the frame 20 is a high gloss coating which more or less approximates the appearance of the normal scalp. The first coat is a very thin coat and sprayed evenly across the hairs 18, the coat being allowed to set for a period of time, as in the neighborhood of one hour. A plurality of coats of medium matte acrylic polymer emulsion are sprayed, one after another, over the initial coat. Each of the plurality of coats is very thinlyand evenly applied without drying in between, and the plurality of coats are allowed to dry, preferably under a blower emitting drying air at 150 degrees Fahrenheit. Following the drying of the plurality of coats, another four or so coats are thinly and evenly applied across the exposed ends of the hairs and these coats are also allowed to dry. The total depth of the first coat and the plurality of coats of acrylic polymer emulsion material may be in the vicinity of one-third of the length of the exposed ends of the hairs 18.

After the thermoplastic coats are dry, an epoxy resin adhesive of any well-known type is properly mixed, as between the resin and the catalyst, and the epoxy resin adhesive is spread across the dried coats of thermoplastic material and over the hairs 18 extending thereabovc. The adhesive is spread relatively thinly, to a depth of about one-third of the inner ends of the hairs, and is carefully spread so as to surround and contact as many of the hairs as possible. It is desirable that each and every inner end of the hairs 18 be surrounded by the epoxy resin adhesive to prevent later disassociation of the hairs from the hairpiece. After the epoxy resin adhesive is spread across the hairs, the adhesive is allowed to set for a short period of time, perhaps one hour, with blower heat at approximately 150 degrees Fahrenheit.

Following the drying of the epoxy resin adhesive, another thin coat of acrylic polymer emulsion is applied over the adhesive coating and allowed to dry for a period of time. Following this drying, a plurality of coats of thermoplastic material are then sprayed one after another thinly and evenly to the top of the inner ends of the hairs 18, the total of this series of coats of thermoplastic material being again approximately one-third of the length of the inner ends of the hairs exposed above the magnetic strips.

The entire base structure is then allowed to set for a 12-hour or so period, following which a light coat of matte gloss of the thermoplastic material is applied and allowed to set.

The base structure is now formed and retains the hairs in place to an extent that the base and the hairs may be removed from the retaining and transfer frame. The clamping forces 22 are released and the magnetic strips, or whatever other devices are used, may be removed. The hairpiece is then removably secured on a head form in the proper position to obtain the correct curvature of the base. Such location on the head form is marked from the original pattern taken from the head of the wearer. When properly mounted on the head form, the hair may be shaped; that is, combed or otherwise laid to the proper direction to be compatible with the remaining hair of the wearer. For example, the hairpiece may be so located as to include a portion of the natural part of the wearer and it would be desirable to have the hairs on one side of the part lay in one direction and the hairs on the opposite side of the part lay in another direction. This is done on the head form and the hairs held in place in some suitable manner, as by masking tape or the like.

The head form and shaped hairpiece are then placed in a curing oven at a temperature of approximately 200 degrees Fahrenheit and left for an extended period of time, such as six hours. Such curing allows the epoxy resin adhesive to cure to its final stage and with the hairs properly shaped and directed, a degree of movement of the hairs within the base structure will take place so that the hairs will properly lay in the correct direction on the hairpiece.

Upon removal of the head form and the hairpiece from the curing oven, the base will now be curved to the shape of the wearers head and may be trimmed to the exact pattern shape. Suitable edging may be applied to thehairpiece in any convenient manner and when the hairpiece is mounted on the head of the wearer, in the proper orientation and position, the hairs may be trimmed and shaped to be compatible with the remaining natural hair of the wearer.

lt will be apparent from the foregoing that the base structure of the hairpiece comprises a laminate of thermoplastic material, epoxy resin adhesive and thermoplastic material, the laminate being very thin and each of the sections comprising about one-third of the depth of the base. The thermoplastic materials are themselves laminates of a plurality of coats of thermoplastic material and since the overall depth is in the vicinity of one-sixteenth to one thirty-second of an inch the base structure will retain a certain degree of flexibility or resilience to permit proper shaping and mounting on the wearers head. At the same time, since the outer coating is a thermoplastic material, it is possible to reshape the direction of lay of the hairs from time to time as the desires of the wearer dictate by reheating and redirecting the hairs as they extend through the upper layer of the laminate. Thus a great deal of control is maintained over the shaping of the hairs in the hair-pieces, not only during the manufacturing process but following such process and as the desires of the wearer change.

It will also be apparent that the hairpiece is of extremely small bulk and thus very lightweight and comfortable for the wearer. inasmuch as the outer shell of the laminate is an acrylic polymer emulsion, and thus an extremely protective material, the hairpiece will not be adversely affected by hair sprays, setting gels, hair tonics or the like, and the effects of weather will be minimized. Similarly with the inner surface of the hairpiece, the thermoplastic material protects against natural body oils and acids to prevent destruction of the hairpiece with continued wear.

Thus, a hairpiece is provided that is efficient and economical to manufacture, produced by a method that is simple and inexpensive and using readily available materials. The method provides great control over the lay of the hairs, simplifying the shaping of the hairs for compatibility with the remaining hair of the wearer.

What is claimed is:

1. A method of making an artificial hairpiece from natural hairs and comprising:

laying up said hairs in retaining andtransfer means;

trimming the inner ends of said hairs to substantially uniform and short length;

applying a first plurality of thin coats of thermoplastic material over a portion of the lengths of the inner ends of said hairs to form a subbase;

applying a coating of epoxy resin adhesive material over said subbase and along a further portion of said lengths of the inner ends of said hairs;

applying a second plurality of thin coats of said thermoplastic material over said epoxy resin adhesive material and covering the remaining portions of the length of said inner ends of said hairs and forming with said first plurality of coats and with said epoxy resin adhesive material a base;

removing said hairs and said base from said retaining and transfer frame;

mounting said base and said hairs in a predetermined position on an artificial head form;

shaping said hairs to a predetermined pattern such that said hairs extend outwardly from said base in predetermined directions;

heating said hairs and said base at a predetermined elevated temperature and for a predetermined period of time to cure said thermoplastic materials and said epoxy resin material;

and trimming said hairs to the desired shape for compatibility with the natural hair of the user of said hairpiece.

2. The method set forth in claim 1 wherein said first plurality of thermoplastic material includes a first coat of high gloss material.

3. The method set forth in claim 2 wherein the remainder of said first plurality of coats are eight in number.

4. The method set forth in claim 3 wherein said first four coats of said remainder of coats are allowed to dry at a predetermined temperature and for a predetermined time before application of the other four of said coats.

57 The method set forth in claim 4 wherein the last of said second plurality of coats of thermoplastic material is of a high gloss material.

6. A method of making a hairpiece comprising the steps of:

laying up the hair on temporary retaining and transfer means; trimming the inner ends of said hair to substantially uniform and short length;

spraying said inner ends of said hair with an 'even and thin coat of thermoplastic material and allowing said material to dry;

spraying on said coating of thermoplastic material a plurality of coats of thermoplastic material having a different gloss than said first coat of thermoplastic material;

applying heat to said plurality of coats to dry said plurality of coats;

applying an epoxy resin adhesive material over said plurality of coats of plastic material and partially covering the remaining depth of the exposed inner ends of said hairs and allowing said epoxy resin adhesive material to set in a predetermined time;

spraying a plurality of coats of plastic material over said epoxy resin adhesive material and allowing said coats to dry, said plastic material and said epoxy resin adhesive material forming a base;

removing said hair and said base from said retaining and transfer means and mounting said hairs and said base on an artificial head form;

shaping said hair to a predetermined pattern such-that said hairs extend from said base in desired directions and retaining said hair in said predetermined pattern;

heatingv said hair and said base at a predetermined elevated temperature and for a predetermined period of time to cure said coats and said adhesive;

and trimming said hairs to the desired shape for compatibility with the natural hair of the user of said hairpieces. 

1. A method of making an artificial hairpiece from natural hairs and comprising: laying up said hairs in retaining and transfer means; trimming the inner ends of said hairs to substantially uniform and short length; applying a first plurality of thin coats of thermoplastic material over a portion of the lengths of the inner ends of said hairs to form a subbase; applying a coating of epoxy resin adhesive material over said subbase and along a further portion of said lengths of the inner ends of said hairs; applying a second plurality of thin coats of said thermoplastic material over said epoxy resin adhesive material and covering the remaining portions of the length of said inner ends of said hairs and forming with said first plurality of coats and with said epoxy resin adhesive material a base; removing said hairs and said base from said retaining and transfer frame; mounting said base and said hairs in a predetermined position on an artificial head form; shaping said hairs to a predetermined pattern such that said hairs extend outwardly from said base in predetermined directions; heating said hairs and said base at a predetermined elevated temperature and for a predetermined period of time to cure said thermoplastic materials and said epoxy resin material; and trimming said hairs to the desired shape for compatibility with the natural hair of the user of said hairpiece.
 2. The method set forth in claim 1 wherein said first plurality of thermoplastic material includes a first coat of high gloss material.
 3. The method set forth in claim 2 wherein the remainder of said first plurality of coats are eight in number.
 4. The method set forth in claim 3 wherein said first four coats of said remainder of coats are allowed to dry at a predetermined temperature and for a predetermined time before application of the other four of said coats.
 5. The method set forth in claim 4 wherein the last of said second plurality of coats of thermoplastic material is of a high gloss material.
 6. A method of making a hairpiece comprising the steps of: laying up the hair on temporary retaining and transfer means; trimming the inner ends of said hair to substantially uniform and short length; spraying said inner ends of said hair with an even and thin coat of thermoplastic material and allowing said material to dry; spraying on said coating of thermoplastic material a plurality of coats of thermoplastic material having a different gloss than saId first coat of thermoplastic material; applying heat to said plurality of coats to dry said plurality of coats; applying an epoxy resin adhesive material over said plurality of coats of plastic material and partially covering the remaining depth of the exposed inner ends of said hairs and allowing said epoxy resin adhesive material to set in a predetermined time; spraying a plurality of coats of plastic material over said epoxy resin adhesive material and allowing said coats to dry, said plastic material and said epoxy resin adhesive material forming a base; removing said hair and said base from said retaining and transfer means and mounting said hairs and said base on an artificial head form; shaping said hair to a predetermined pattern such that said hairs extend from said base in desired directions and retaining said hair in said predetermined pattern; heating said hair and said base at a predetermined elevated temperature and for a predetermined period of time to cure said coats and said adhesive; and trimming said hairs to the desired shape for compatibility with the natural hair of the user of said hairpieces. 